Processing substrate and/or support surface

ABSTRACT

A processing substrate includes a first cut-resistant layer having a first surface area and including an absorbent ply and a thermoplastic material ply and a second layer having a second surface area and including an absorbent ply and a thermoplastic material ply. The thermoplastic material ply of the second layer is tinted a certain color for indicating absorption of the absorbent ply of the second layer.

RELATED CASES

[0001] This application is a continuation-in-part of Ser. No.10/075,020, filed Feb. 12, 2002, entitled “Processing Substrate and/orSupport Surface,” which is a continuation-in-part of Ser. No.09/677,663, filed Oct. 2, 2000, entitled “Processing Substrate and/orSupport Surface.”

TECHNICAL FIELD

[0002] The present invention relates generally to protective media, and,more particularly, to a processing substrate and/or support surfacewhich is disposable.

BACKGROUND ART

[0003] Management of bacteria, liquids, fats and other waste during thepreparation and handling of foods is of concern in food handling areas.Typically, such areas include the kitchen, although modem lifestylesinclude out-of-home occasions such as social and recreational gatheringswhere food is prepared, transported and/or served outside of thekitchen. Foods of particular concern from the standpoint of possibilityof food-borne illness are fish, fowl and ground meats; although allfoods present some degree of risk. Current media articles discuss thefact that the common cutting boards used in the preparation of foods area source of food contamination. Other commonly used food preparationsurfaces, such as countertops, also present some risk. Specifically, ithas been found that bacteria can become entrapped in surfaceimperfections of the cutting surface, resulting in a surface that isdifficult, if not impossible, to clean and/or sterilize. The cuttingsurface thus becomes capable of transferring bacteria to other foods,which provides a favorable media for pathogens to proliferate, resultingin an increased potential for food-borne illness, particularly whencontact is had with high-risk foods. In fact, some foods considered tobe pathogenically low-risk, such as fresh fruits and vegetables canbecome contaminated, waiting for the right environment for the bacteriato proliferate.

[0004] Another issue with cutting boards is the transfer of juices fromthe cutting board to other surfaces in the kitchen due to the fact thatthe cutting board is normally not designed to capture and contain juicesduring the cutting operation and thereafter through final disposal. Inaddition to the inconvenience of having to clean the countertop or othersurface(s) exposed to the juices, a possibility exists that other fooditems placed on such surface(s) may be cross-contaminated.

[0005] Products are in the marketplace today that attempt to addressissues of liquid, fat, and bacteria management during cutting andgeneral food preparation. However, these products fall short of optimumin one way or another. Specifically, they do not absorb, are not cutresistant, and/or fail to provide an effective bacteria barrier betweenthe food being handled and the work surface. Also, bacteria are retainedwhich can cause contamination during subsequent use.

[0006] In addition to the foregoing, most, if not all, food preparationsurfaces lack one or more of the following attributes:

[0007] 1. a single use, disposable cutting surface that is virtually cutresistant and also entraps and holds waste and bacteria;

[0008] 2. a food preparation surface which prevents food movement duringcutting;

[0009] 3. a food preparation surface which prevents and/or selectivelymanages movement thereof on the counter top during cutting;

[0010] 4. a single-use food preparation surface which is easily disposedof while securely containing contaminants; and

[0011] 5. a single-use cutting surface that lays flat during use.

[0012] Coggins U.S. Pat. No. 5,520,945 discloses a disposable sheet thatmay be used in food service applications to prevent thecross-contamination of foods and eliminate the need for time-consumingclean-ups. The sheet comprises a porous layer that allows materials suchas oil or flour to pass through, an absorbent layer that holds thematerials passing through the porous layer, and a barrier layer thatensures that the materials do not contaminate a food preparationsurface. The sheet has multiple uses such as for rolling dough,absorbing excess moisture, making sandwiches, cutting breads andcondiments, and drawing excess oil away from fried items. The disposablesheet is only disclosed for use with items that do not requireaggressive cutting, and hence, is not adapted for use with items thatrequire substantial cutting pressures, such as meats and hardvegetables.

[0013] Thompson U.S. Patent No. Re. 36,717 discloses a flexiblepreparation and transfer sheet. The sheet comprises a homogeneousstructure of polypropylene, with a thickness in a range between 0.010 to0.030 inch. The sheet may be flexed about a longitudinal centerlinewhereupon the sheet material develops a cantilever beam strengthsufficient to transport food articles after preparation to anappropriate container.

[0014] Wu et al. U.S. Pat. No. 6,021,524 discloses a polymeric filmhaving increased cut resistance. The film comprises a polymeric matrixhaving a plurality of cut resistance fibers dispersed therein. The filmis preferably made into medical or industrial gloves.

[0015] Otten et al. U.S. Pat. No. 6,274,232 discloses an absorbent andcut-resistant sheet having a cut-resistant material with a plurality ofopenings, and an absorbent material attached to the cut-resistantmaterial. A liquid impervious backing layer is preferably attached tothe absorbent material to resist the escape of fluid from the absorbentmaterial.

[0016] PCT published application number WO 00/29209 discloses a flexiblemat for absorbing liquids on floors or other surfaces. The mat includesa waterproof backing layer and a foam sheet formed by polymerization ofa water-in-oil emulsion. The mat can optionally include a liquidpervious sheet and a non-skid material.

SUMMARY OF THE INVENTION

[0017] In accordance with one aspect of the present invention, a singleuse processing substrate includes a first cut-resistant layer having afirst surface area and including an absorbent ply and a thermoplasticmaterial ply and a second layer having a second surface area andincluding an absorbent ply and a thermoplastic material ply. Thethermoplastic material ply of the second layer is tinted a certain colorfor indicating absorption of the absorbent ply of the second layer.

[0018] According to a further aspect of the present invention, asingle-use processing substrate comprises a first material having aliquid-permeable, cut resistant surface and a second material disposedadjacent the first material and having a liquid-absorbent portion. Theprocessing substrate further includes a third material disposed adjacentthe second material and having a liquid-impermeable portion, wherein thethird material is tinted a certain color to indicate absorption of theabsorbent portion.

[0019] In accordance with yet another aspect of the present invention, asingle-use processing substrate includes first means for providing aliquid-permeable, thermoplastic, cut resistant surface having aperturestherein and second means disposed adjacent the first means and providingmeans for providing a liquid-absorbent portion. The processing substratefurther includes third means disposed adjacent the second means andproviding means for providing a liquid-impermeable portion and fourthmeans for providing an indication of absorption of the second means.

[0020] Other aspects and advantages of the present invention will becomeapparent upon consideration of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021]FIG. 1A comprises an isometric view of a processing substrateaccording to one embodiment;

[0022]FIG. 1B comprises an isometric view of a processing substrateaccording to another embodiment;

[0023]FIG. 2 comprises a side elevational view of the processingsubstrate of FIG. 1;

[0024]FIG. 3 comprises a sectional view taken generally along the lines3-3 of FIG. 1;

[0025]FIG. 4 comprises a perspective view of apparatus for producingprocessing substrates as shown in FIG. 1A;

[0026]FIG. 5 comprises an isometric view of a processing substrateaccording to another embodiment;

[0027]FIG. 6 comprises an isometric view of a processing substrateaccording to another embodiment;

[0028]FIG. 7 comprises a cross sectional view of FIG. 6;

[0029]FIG. 8 comprises an isometric view of a processing substrateaccording to another embodiment;

[0030]FIG. 9 comprises an isometric rear view of a processing substrateaccording to FIG. 8;

[0031] FIGS. 10-13 comprise plan views of processing substratesaccording to other embodiments;

[0032]FIGS. 14 and 15 comprise isometric views of processing substratesin roll form;

[0033] FIGS. 16-19 comprise cross sectional views of processingsubstrates according to other embodiments;

[0034]FIG. 20 comprises an elevational view of a processing substrateaccording to another embodiment;

[0035]FIG. 21 comprises a cross sectional view of a processing substrateaccording to another embodiment;

[0036]FIGS. 22 and 23 comprise isometric views of apparatus forproducing processing substrates according to further embodiments;

[0037]FIG. 24 comprises a cross sectional view of a processing substrateaccording to another embodiment;

[0038]FIG. 25 comprises a plan view of the absorbent ply of the toplayer of a processing substrate according to a further embodiment;

[0039]FIG. 26 comprises a plan view of the absorbent ply of the toplayer of a processing substrate according to another embodiment;

[0040]FIG. 27 comprises an isometric view of an apparatus for producinga processing substrate as shown in FIG. 25;

[0041]FIG. 28 comprises an isometric view of another apparatus forproducing a processing substrate as shown in FIG. 25;

[0042]FIG. 29 comprises a plan view of a processing substrate accordingto a further embodiment;

[0043]FIG. 30 comprises a sectional view of a first embodiment of theprocessing substrate of FIG. 30 along the lines 30-30;

[0044]FIG. 31 comprises a sectional view of a second embodiment of theprocessing substrate of FIG. 30 along the lines 30-30;

[0045]FIG. 32 comprises a plan view of a processing substrate accordingto another embodiment;

[0046]FIG. 33 comprises a sectional view of the processing substrate ofFIG. 32 along the lines 33-33; and

[0047]FIG. 34 comprises a perspective view of an apparatus for producingthe processing substrates of FIGS. 29-33.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] Referring now to FIG. 1A, a processing substrate and/or supportsurface that may be used as a food preparation surface or sheet 10preferably is planar (i.e., flat) in shape. Alternatively, as seen inFIGS. 1B and 2, the sheet 10 may be tray-shaped and includes asubstantially planar central portion or base 12 and inclined or curvedside surfaces 14 a-14 d, wherein the base 12 and side surfaces 14together define a generally concave structure. The side surfaces 14 maybe formed by folding and/or scoring the sheet 10 at corner portions 15a-15 d and optionally folding or scoring the sheet 10 at portions 13a-13 d intermediate the base 12 and side surfaces 14. The inclined orcurved side surfaces 14 could alternatively be formed by any otherprocess, such as forming through the application of heat, vacuumforming, vacuum pressure forming, or the like. If desired, fewer thanfour inclined side surfaces 14 may be provided. For example, only theinclined side surfaces 14 a-14 c may be employed to provide a flat edgesurface that may be oriented toward the user so that an inclined sidesurface does not interfere with the user's hands or arms. Preferably,although not necessarily, the sheet 10 is intended for one time use as acutting surface or as a sheet supporting an article or as a barrier forisolating an article resting on a surface (for example, a plant on ashelf, an article of food on a counter or in a microwave, or the like),or as a food preparation and bacteria management sheet. Following theuse the sheet 10 and any waste products and contaminants carried therebymay be disposed of in any suitable fashion. The concave or tray-shapedstructure (if used) facilitates retention of the waste products andcontaminants during the food preparation, transport and/or disposalprocesses. Additionally or alternatively, the sheet 10 may besufficiently flexible to allow the user to bend and/or fold the sheet 10to prevent escape of waste products and contaminants therefrom duringdisposal.

[0049] Referring also to FIG. 3, according to one embodiment, the sheet10 also includes a cut-resistant, liquid-permeable top or upper portionor layer 16, which substantially prevents the integrity of the sheet 10as a whole (and, in particular, the layer 16) from being compromisedduring cutting while at the same time allowing passage of juices andliquids through the layer 16. Preferably, the upper portion or layer 16is made of a material sufficiently durable to withstand aggressivecutting of meats, vegetables and other food items by a serrated ornon-serrated blade, particularly in the situation where a cutting motionis applied to meats, poultry or fish (or any other fibrous proteinmaterial) that results in the application of cutting force components inmultiple directions to the item. A serrated blade presents a series ofequally or non-equally spaced points or tips to the upper surface of thelayer 16 that can snag or otherwise catch on edges of the material usedfor the top layer 16. Because of this it is generally preferred(although not necessarily the case) that the top layer 16 haveirregularly or randomly spaced openings therein that prevent any pointsor tips from contacting material below the layer 16 during cutting. Inthis way, the possibility that the integrity of the sheet 10 would becompromised is reduced.

[0050] In addition to the foregoing, the upper portion or layer 16preferably has an upper surface 17 that is textured or otherwise formedto prevent slippage of items thereon during processing.

[0051] The sheet 10 further includes a middle or intermediate portion orlayer 18 that may be made of a liquid absorbent material that retainsthe juices and liquids passed by the upper layer 16, as well as a bottomportion or layer 20, which is preferably made of a slip-resistant,liquid, and bacteria impervious material to prevent slipping of thesheet 10 and leakage of liquids and transfer of bacteria onto or from awork surface (such as a countertop, a cutting board, or the like) duringuse.

[0052] The upper layer 16 may be of a length and width substantiallyequal to the length and width of the middle layer 18. Alternatively, theupper layer may be of a smaller size than the size of the layer 18,thereby providing a cutting surface that is partially or fullysurrounded by portions of the middle layer 18. As a further alternative,the top and bottom layers 16, 20 may be of the same size and the middlelayer may be of a smaller size and so arranged relative to the layers 16and 20 such that the middle layer 18 is surrounded by the joined outermargins of the layers 16 and 20.

[0053] If desired, the sheet 10 may instead include a different numberof layers or portions each imparting one or more desiredcharacteristic(s) to the sheet 10. In addition, the sheet 10 maycomprise a single layer or portion or multiple layers or portionswherein each layer or portion is made of material that is differentiallytreated during production to obtain multiple desired characteristics.Still further, the sheet 10 may include one or more layers or portionsthat are not differentially treated during production in combinationwith one or more layers that are differentially treated duringproduction. For example, the sheet 10 could comprise a single layer thatis liquid absorbent, but which has a first surface that is treated (byany suitable process, such as the application of heat or a chemicaladditive) during production to produce a cut-resistant, liquid-permeablesurface. The sheet 10 may further have a second surface opposite thefirst surface that may be treated by any suitable process (for example,as noted above) during production to produce a slip-resistant barriersurface. Alternatively, the sheet 10 could comprise two layers, a firstof which provides a slip-resistant barrier surface, and a second ofwhich provides a cut-resistant surface. In this case, the liquidabsorbent layer may be omitted, or the liquid-absorbent material may beprovided as part of one of the first or second layers or as a separatelayer. Still further, the slip-resistant surface and/or thecut-resistant, liquid-permeable surface could be omitted, if desired.

[0054] The various layers 16, 18 and 20 are secured or formed togetherin any suitable fashion taking the various materials of the layers intoaccount. For example, two or more of the layers 16, 18, and 20 may beheated to fuse the layers together or the layers may be laminated aspart of an extrusion process. Two or more of the layers could instead besecured together by an adhesive including a hot melt adhesive as well asa solvent or water based adhesive, as long as the adhesive is approvedfor food contact and compatible with the layers. Alternatively, two ormore of the layers 16, 18, and 20 may be formed using materials and/or amanufacturing process which result in simultaneous formation and bondingof such layers. Still further, the layer 16 may be bonded or otherwisesecured to the layer 20 at selected locations, thereby capturing thelayer 18 therebetween. In this case, the layer 18 may have one or morevoids therein to facilitate the joinder of the layers 16 and 20 at thelocation(s) of the void(s). Still further, the layer 18 may be omittedand the layers 16 and 20 may be joined at spaced locations to createvoids between the layers 16, 20 which serve to attract and retainliquid(s) therein by capillary action.

[0055]FIG. 4 illustrates an apparatus that may be used to produce anumber of cutting surfaces as shown in FIG. 1A. An extrusion die orother delivery device 40 deposits thin streams of molten thermoplasticonto a web 42 of liquid-absorbent material, such as cellulosic tissue orbatting. The material deposited on the web 42 is chosen from but notlimited to polyolefins, such as polyethylene (PE), polyolefinmetallocenes, metallocene polypropylene (mPP) or polypropylene (PP)including homopolymers and copolymers thereof, polyester, such aspolyethylene terephthalate (PET), polystyrene (PS), polyvinyl alcohol(PVA), polyvinyl chloride (PVC), nylon (such as nylon 6 or nylon 66),polyacrylonitrile (PAN), acrylonirile-butadiene-styrene (ABS),ethylene-vinyl acetate (EVA) copolymer, multi layers of the same ordifferent polymers, blends and recycled polymers (including polymersthat are cured by ultraviolet or visible light, an electron beam, wateror other curing agent). Addition of one or more filler(s) may beadvantageous both from a cost advantage as well as improvement ofmodulus, heat distortion and cut resistance. Preferably, each stream isapproximately on the order of 1-100 thousandths inch (0.0254 mm-2.54 mm)wide and are deposited at equally-spaced locations on the web 42approximately 1-500 (0.025 mm-12.7 mm) thousandths inch apart.Alternatively, the streams may be deposited at non-equally spacedlocations on the web 42 and/or may be of differing widths and/or may bedeposited at different points of time. Still further, different streamshapes (e.g., a wavy, curved, discontinuous or interrupted stream asopposed to the linear continuous stream extent described above and/or adifferent cross-sectional shape) and/or different materials could besequentially deposited on the web 42. In other words, a single streammay comprise a first portion of a first material, a second portiondeposited after the first portion of a second material, a third portiondeposited after the second portion of a third material or the firstmaterial, etc. In an alternative embodiment, adjacent streams may be ofdiffering materials. In a general sense, N different materials may bedeposited or otherwise formed in situ on the web 42 in a repeating ornon-repeating sequence or pattern or in a random fashion. In the case ofa repeating sequence or pattern, the repetition frequency may beestablished at a value less than or equal to N. In any event, the choiceof materials, sequence or pattern, and the like affect the physicalcharacteristics of the resulting surface.

[0056] If the upper layer 16 is to be smaller than the size of the layer18, then the streams are deposited only on a center portion of the web42. In addition, the flow of thermoplastic resin is periodicallyinterrupted so that discrete portions of web are formed havingthermoplastic thereon wherein such portions are separated by further webportions not having thermoplastic deposited thereon. The web 42 thenpasses between a pair of rolls 44 a, 44 b. Preferably, the roll 44 a issmooth and the roll 44 b has a plurality of diamond-shaped or othershaped protrusions 46 on the surface thereof. The protrusions 46 deformand spread out the still molten thermoplastic streams to transform thelinear streams into a desired two or three dimensional pattern ofthermoplastic resin on the web 42. The web 42 then passes between one ormore additional pairs of rolls 48 that further spread out and/or flattenthe thermoplastic streams and impart a desired texture thereto. Theresulting surface provides cut resistance and prevents food from slidingthereon

[0057] If desired, any pattern can be created on the web 42, forexample, a random pattern or a crisscross pattern could be created bydrizzling, spraying or otherwise applying the material thereto.

[0058] Thereafter, the web 42 is inverted (i.e., turned over) and thelayer 20 is formed in situ by lamination or other delivery of athermoplastic or other material onto an undersurface 50 by an extrusiondie or other delivery apparatus. The layer 20 may alternatively beformed without first inverting the web 42 by any suitable process. Thelayer 20 may be formed of any of the materials described above inconnection with the layer 16 including polyolefins such as PE or PP,polyesters such as PET, PS, PVA, PVC, nylon, PAN, ABS, EVA, etc. . . .In alternative embodiments, a suitable coating material may be appliedby a sprayer and mechanically processed by a doctor blade or a portionof the material of the layer 18 may be melted or otherwisedifferentially processed as noted above so that a sealed portion isobtained (if the material of the layer 18 so permits). Still further, abarrier layer of TYVEK® (sold by E. I. Du Pont de Nemours and Company ofWilmington, Del.) may alternatively be secured to the underside of theweb 42 by any suitable means.

[0059] The layer 20 may be formed with a pattern or texture by embossingand/or may be coated or laminated or otherwise formed with aslip-controlling (such as slip resistant) or adhesive material. The slipcontrol may be provided by a continuous or discontinuous surface of thelayer 20, as desired. The resulting coated web is then cut atappropriate locations to form the cutting sheets.

[0060] The processing substrate as described herein is not limited tothe concept of utilizing disposable, absorbent barrier surfaces in placeof conventional cutting boards, but encompasses all food handling andarticle support occasions where absorbent, liquid/bacteria barriermanagement is desirable. The processing substrate can have arrangementsof various barriers, absorbent and cut/physical abuse resistantmechanisms for the management by containment or isolation of wastes andbacteria encountered during food processing, such as cutting, drainingand accumulating (staging). All of these processes involve the use of agenerally horizontal work surface, where the embodiments herein may beadvantageously employed. In general, of the processing substrate mayinclude N layers or other portions which may be arranged in a suitableor desired fashion to obtain the desired mechanical, absorbent, barrier,and/or other characteristics.

[0061] A preferred embodiment utilizes the cut resistant layer 16 as thetop layer, where the cutting operation is performed. If desired, thelayer 16 may be omitted and the cut-resistant surface could instead beprovided as part of the bottom layer 20. In this case the cut-resistantsurface would need to be impervious to liquid and the material of themiddle layer 18 could be exposed directly to the item being cut. Thisalternative may result in the possibility of material transfer from thelayer 18 to the food, although such possibility can be minimized throughcareful control of materials and design. For example, in an embodimentwhere the liquid absorbent layer 18 is the top layer, effort should bemade to ensure minimum transfer of material (e.g., fibers) to the foodbeing cut. In the case of paper, woven or nonwoven fabrics as thematerial of the liquid absorbent layer 18, thermal bonding of fiber tofiber in such layer and/or fiber of such layer to the material of thebottom layer 20 significantly reduces fiber transfer to the food. Manyother commercially available techniques for minimizing transfer ofmaterial(s) exist. For example, various thermal embossing patterns couldbe used. Care should be taken to ensure that the absorptive capacity ofthe material of the layer 18 is minimally affected by the mode ofbonding.

[0062] Other arrangements can be envisioned, such asthermoplastic/cellulosic conglomerates or agglomerates. In thesearrangements thermoplastic and cellulosic absorptive materials arecompressed together or otherwise processed and/or combined to form a cutresistant, absorptive sheet. When a thermoplastic liquid barriercomponent is fused on one side, a cut resistant, absorptive, barriersystem is formed.

[0063] Still further, each layer or portion may be “tuned” (in otherwords, the material selection, properties and/or amounts may becontrolled) to obtain the desired attributes and properties for each.For example, a first sheet could be designed for cutting chickencomprising an upper layer of PE or PP, a middle layer of cellulosicabsorbent material and a barrier layer of polymeric material asdescribed above in connection with FIG. 4. A second sheet couldalternatively be envisioned for light food preparation (such asassembling sandwiches from pre-cut foods) including the same threelayers in different proportions. This might comprise an upper layer ofPE or PP having a thickness substantially less than the thickness of theupper layer of the first sheet, a middle layer of cellulosic absorbentmaterial identical to the material of the middle layer of the firstsheet and a barrier layer of polymeric material identical to thematerial of the barrier layer of the first sheet. The thicknesses of themiddle and barrier layers of the second sheet may be different than oridentical to the thicknesses of the same layers of the first sheet. Thisprovides a sheet having lesser cut resistance than the first sheet, butstill provides a sheet having the desired absorbency and barriercharacteristics appropriate to the intended application for the sheet.Still further, the cellulosic material of the middle layer might bereplaced by a more oleophilic material, such as nonwoven polypropyleneor the same or a different cellulosic material that has been treated toincrease the oleophilic properties thereof, to form a sheet for managingoil during food preparation.

[0064] Any of the embodiments disclosed herein provide a processingand/or support surface that retains liquids yet is convenient and spaceeffective for easy disposal. The product may be pre-treated forpackaging purposes and/or to allow easy and convenient disposal.Examples of pretreatment for easy disposal include pleating, folding,scoring, forming and the like.

[0065] As noted above, the cut resistant top layer 16 may be made from arandom or regular pattern of thermally formable material or coatingmaterials. In addition to the examples given above, the material of thelayer 16 may comprise latexes, epoxies, paper coating and a contact drumprint that is treated by a doctor blade. Still further, a continuoussheet of polymer film could alternatively be used in place of thecut-resistant upper layer described in conjunction with FIG. 4, whereinthe film is perforated by any suitable process, such as vacuum, needleor water jet perforating, laser, hot pins or mechanical punching tocreate holes for the passage of liquid therethrough. A minimum holediameter of between about 0.060 and about 0.125 thousandths inch(0.003175 mm 0.001 524 mm) is preferred. Less than 8 holes/square inch(depending upon hole size(s)) is preferred. The spacing between the tipsof serrated knife blades vary; however, the smaller the hole diameter,the less the chance that a tip of such a blade will catch on an edge ofa hole. The film can be made of virgin polymer or blends of virgin andrecycled materials or from recycled materials alone. As noted above,fillers or pigments to increase opacity, optimize desired properties,and/or reduce cost are options. Alternatively, porosity can be achievedusing different processes such as pre- or post-lamination, lost massprocess, leaching or scavenging.

[0066] The cut resistant layer 16 can alternatively comprise other cutresistant structures, such as netting, fabrics or scrims, so long as thelayer allows easy passage of juices and other liquids through to theabsorbent layer 18. In each embodiment, the minimum thickness for thelayer 16 is approximately 5 mils (0.127 mm) for unfilled materials, butit may be possible to achieve adequate cut resistance with thinnerarrangements.

[0067] Care should be taken to use food contact approved materials. Theuse of a discontinuous layer affords a cut resistant barrier that keepsthe material of the layer 18 from the surface of the item being cut.Also, the discontinuous layer lends itself to being easily disposed ofdue to ease of “wadding” by the user

[0068] The liquid-absorbent layer 18 preferably is an absorbentstructure selected from, but not limited to: non-woven fabrics ofsynthetic polymers or blends of fibers; laminates of various fabrics orcombination of fabrics; cellulosic material(s), meltblown and spunbondednonwoven fabrics, woven fabrics, multiple layers and combinations offabrics and papers, absorbent powders like polyacrylic acid polymers,open-celled foams, perforated closed cell foams and/or blends of polymerand cellulosic materials. The layer 18 could alternatively comprise anyother suitably absorbent commercially available materials.

[0069] If a synthetic polymer fabric, woven or nonwoven, is used for thelayer 18, a food-contact approved wetting agent or other surfaceadditive may be required to ensure water wettability of the fabric.Typical levels are <1% by weight of the fabric. Some hydrophilic fiberscan be used for layer 18 in blends with synthetic polymers to eliminatethe need for surfactants. Examples of these hydrophilic fibers arecellulose, rayon and PVA; however, the applications herein are notlimited to these hydrophilic fibers. In some cases, lamination of twodifferent fabrics may be necessary to obtain sufficient hydrophilicproperties. However, it is preferred in this example, to use a blend offibers in one fabric. Typically, a minimum of 5 to 10% hydrophilic fiberis needed in a fiber blend to ensure that the fabric has sufficienthydrophilic properties. An additional benefit of using fiber blends inthe layer 18 is the possibility to use different polymers in the layer16 and still employ thermal bonding of the layers.

[0070] The bottom layer 20 forms a barrier to prevent liquids from theabsorbent layer 18 from passing through to the surface of the countertop or other support surface. The bottom layer 20 also blocks thetransfer of bacteria between the layers 16 and 18 and the surfacesupporting the sheet 10. The bottom layer 20 can be any substratematerial that prevents passage of liquid therethrough. For example, thelayer 20 may comprise a continuous sheet of PP or PE film (or any otherpolymer film, such as those noted above) having a thickness on the orderof 0.25-5.0 mils (0.00635-0.127 mm), although a different thicknesscould be used instead. Fillers and/or coloring agents or other additivescan be utilized to obtain the desired characteristics, color and/oropacity. Like the layer 16, the film can be made of virgin polymer orblends of virgin and recycled materials or from recycled materialsalone. Typically, the layer 20 is fabricated of materials chosen from agroup of materials that will thermally bond to the layer adjacentthereto (in the preferred embodiment the layer 18), thereby obviatingthe need for adhesives, which are costly and can adversely affect thedesired characteristic (e.g., the absorbent nature) of the adjacentlayer.

[0071] In summary, the embodiments discussed herein comprehend anystructure (single layer or multilayer, conglomerates, agglomerates,foams, product suspended in one or more matrices or suspensions) havingcut resistant properties, liquid-absorbent properties and/or barrierproperties. The properties may be afforded by any suitable processingtechnique(s), such as coating or other application of product,denaturing or other change in a material (whether by flame treating orother application of heat, chemicals, irradiation, UV, IR or visiblelight, etc. . . . ), mechanical or electrical processing, or the like.In addition, the various materials may be selected from ecologicallyadvantageous materials that biodegrade.

[0072] In the case of foams, these can be either of the open-cell orclosed cell type made from conventional polyolefins or polyolefin filledmaterials. Still further, a foam can be filled with combinations of anyof the non-conventional materials listed below, such as egg whites andshells or other foams could be used with fillers like mica, starch, woodflour, calcium carbonate, and flax. Other suitable materials may bebread impregnated with adhesive binders, foamed potato starch orpolyvinyl acetate with any number of fillers like ground bone, lime ortalc. Other suitable foams are polyvinylpyrollidone aggregate open cellfoams and PE and PP aggregate foams. Such combined materials can providecut resistance and/or liquid absorption properties.

[0073] Hollow fibers could also be employed. In this case, hollow fibersof a critical diameter may be used to suck up and retain water bycapillary action. These fibers could possess cut resistant properties aswell as liquid management properties and a barrier layer could besecured by any suitable means to a mat of such fibers to obtain aprocessing surface.

[0074] The following materials possess one or more of the aboveabsorptive properties, cut resistance properties, and barrier propertieseffective to manage bacteria or liquids during the preparation of food.Accordingly, any of these materials can be used in the embodimentsherein. Some are very eco-effective in that they decompose directly tofood for biocycles and many do not absorb microwave energy and are safefor use as a support surface in microwave ovens:

[0075] “Earth shell” (a composition of potato starch and limemanufactured and/or sold by E. Khashoggi Industries, LLC of SantaBarbara, Calif.);

[0076] clay or clay-filled materials optionally reinforced withmaterials such as ground corncobs, silica, irradiated waste sludge orwoven straw;

[0077] kelp and other marine vegetation;

[0078] ground marine shells (e.g., lobster, crab, shrimp or any otherexoskeletal creatures, oyster, clam, scallop or zebra mussel shells)held together by a binder or matrix of any suitable material, such asbarnacle adhesive;

[0079] cork;

[0080] wood or wood product derivatives and veneers;

[0081] natural fibers like cotton or wool either woven or in non wovenbatts;

[0082] materials such as flour, silica, rice, rice kernel, rice germ orstarch of any kind (e.g., corn or potato starch) either alone or heldtogether by a binder such as polyvinyl acetate or held together asconglomerate or agglomerate systems by any appropriate material(s);

[0083] animal, insect and/or fish products including shells, skins,hides, hooves, glues made from hides or hooves, scales or bones; otherprotein glues or glues from other products (such as gluten);

[0084] egg white or egg yolk composites with flour, rice, egg shells,flours with yeast, corn starch or potato starch;

[0085] lecithin;

[0086] polymeric substances created from high temperature treatment, orother breakdown, of carbon chains predominantly in sugars and oils, suchas is found in apples, grapes, cherries or other fruit (skins and/orpulp), olives (skins and/or pulp), olive oil, corn oil, vegetable oil,canola oil, or eggs;

[0087] bioengineered cell growth materials;

[0088] grasses and other terrestrial vegetation;

[0089] bark;

[0090] nonwoven microfibers;

[0091] cellular absorption swellable materials (such as Drytech® sold byThe Dow Chemical Company of Midland, Mich.);

[0092] molecular sieve materials (e.g., a desiccant); and

[0093] hydrophilic powders, like polyacrylic acid or the like.

[0094] Another embodiment can be seen in FIGS. 5-9. As seen in FIGS.5-9, a bilayer single use processing substrate comprises a first two-plycut-resistant layer 60 and a second two-ply layer 62. The first layer 60has a first surface area 64 and comprises a tissue ply 66 disposed belowa thermoplastic material ply 68. The tissue ply 66 has a thickness inthe range of between about 2 and about 6 mils (0.0508 mm-0.1524 mm) andthe thermoplastic material ply 68 has a thickness in the range ofbetween about 4 and about 8 mils (0.1016 mm-0.2032). The second layer 62has a second surface area 70 and comprises a tissue ply 72 disposedabove a thermoplastic material ply 74. The tissue ply 72 has a thicknessin the range of between about 2 and about 6 (0.0508 mm-0.1524 mm) milsand the thermoplastic material ply 74 has a thickness in the range ofbetween about 1 and about 5 mils (0.0254 mm-0.127 mm). The first layer60 is disposed atop the second layer 62 such that the first layer tissueply 66 and the second layer tissue ply 72 are secured to each other bysuch means as an adhesive or a water soluble polyethylene oxide coatingon first and second layer tissue plies 66, 72, and wherein a portion ofthe second surface area 70 is laterally disposed outside of the firstsurface area 64.

[0095] The adhesive (not shown) can be applied either to the entiresurface of the first layer 60 or can be applied in any number ofpatterns, including without limitation interrupted patterns such as aseries of spaced spots and continuous patterns such as parallel stripesor interlocking stripes. One preferred pattern is a series of parallelstripes. It has been found that this pattern adds a capillary effect tothe processing substrate by slightly separating the sheets. Thisseparation creates a capillary effect that helps draw liquids away fromthe surface of the cut resistant layer 60. Also, these parallel stripeschannel the liquid toward that portion of layer 62 that is not coveredby layer 60 in the preferred embodiment.

[0096] Each of the first and second layers 60, 62 can be produced byextrusion coating the thermoplastic material ply onto the tissue ply ina manner similar to the process illustrated in FIG. 4. While thethermoplastic material plies can be formed from any of the thermoplasticmaterials described above, a preferred material is an isotacticcopolymer metallocene polypropylene, wherein the metallocenepolypropylene comprises between about 95 and about 99.95, and preferablybetween about 99.5 and about 99.9 percent by weight of a propylenemonomer and between about 0.05 and about 5, and preferably between about0.1 and about 0.5 percent by weight of an ethylene monomer.

[0097] The surface of each thermoplastic material ply can range fromsmooth to rough. While the two surfaces can both have similar surfacecharacteristics, in one preferred embodiment, the top surface of the cutresistant layer 60 can be smooth and the bottom surface of the secondtwo ply layers can be rough or have a matte appearance. The method ofcreating these surface effects is well known to those skilled in the artof film production. One method of producing these effects is to use afilm casting roll that mirrors the desired roughness of the film. Forsmooth films, the roll can have a root mean square of about 0.05 toabout 5 and for the matte surface the roll can have a root mean squareof over about 100.

[0098] The most preferred resin composition comprises between about 90and about 100 percent by weight of the metallocene polypropylene and canfurther include any combination of the following components: an additiveselected from the group of talc, mica, wollastonite, calcium carbonate,barite, glass spheres and fibers, carbon fibers, and ceramic spheres,present in an amount of between about 0 and about 10 percent by weight,a food contact grade alkali metal stearate such as calcium stearate,magnesium stearate and the like or a food contact grade transition metalstearate such as zinc stearate and the like present in an amount ofbetween about 0.01 and about 0.1 percent by weight, and one or moreantioxidants, such as Alvinox P, Irgaphos 168, Alkanox 240, Iraganox3114, Iraganox 1010, Anox IC 14, and Alvinox FB, present in an amount ofbetween about 0 and about 0.25 percent by weight. Small amounts of otheradditives (nucleation agents, clarifiers and pigments) or processingaids can also be included so long as they do not negatively affect theoverall performance properties of the material. Preferably, additivesmust be approved for direct food contact. It is believed that the talcadditive speeds crystalline formation in the polypropylene and improvesthe cut resistant properties of the polymer, whereas a metal stearateserves as a film lubricant for the polypropylene during processing.

[0099] The first layer tissue ply 66 and the second layer tissue ply 72may be provided by an outside paper provider such as Little RapidsCorporation. Each of the first and second layer tissue plies 66, 72comprise a virgin hardwood and softwood wood pulp present in an amountof between about 90 and about 100 percent by weight of the tissue, apolyamide or other synthetic fiber present in an amount of between about0 and about 10 percent by weight of the tissue ply and can include oneor more of the following components in trace amounts: a defoamer, adryer release agent, one or more creping agents, a repulping aid and ableach neutralizer. The components present in trace amounts areadditives which are used as machine runnability aids for the tissue.

[0100] The first layer 60 has a surface area 64 less than the surfacearea 70 of the second layer 62 and is preferably substantially centeredon the second layer 62. In a preferred embodiment, the first and secondlayers 60, 62 have dimensions such that the surface area 64 of the firstlayer 60 is greater than 50 percent and less than 100 percent of thesize of the surface area 70 of the second layer 62. An arrangement oflayers can be used wherein first layer 60 is coextensive with the secondlayer 62 in a first dimension but is smaller than the second layer 62 inthe second dimension. Across the second dimension, the first layer 60can be centered or offset relative to the second layer 62. When thefirst layer 60 is centered, this forms areas or gutters of similarsizes. Where the first layer 60 is offset relative to the second layer62 in a second dimension, either a single area or gutter is formed alongone edge or two different sized areas or gutters can be formed. Thevisibility of that portion of tissue ply 72 of second layer 62 which isnot covered by first layer 60 provides positive reinforcement to theultimate user of the processing sheet that the sheet has absorbent aswell as protective characteristics.

[0101] In a commercial embodiment, the substrate may include the firstlayer 60 having dimensions of between about 6 inches (152.4 mm) andabout 14 inches (355.6 mm) by between about 5 inches (127 mm) and about10 inches (254 mm) and the second layer 62 may include dimensions ofbetween about 10 inches (254 mm) and about 16 inches (406.4 mm) bybetween about 8 inches (203.2 mm) and about 13 inches (330.2 mm). Asseen in FIGS. 6 and 7, the first layer 60 may have regularly spacedapertures 76 therein to permit flow of fluids therethrough. While apreferred arrangement of apertures is a zigzag pattern in the firstlayer 60, wherein the apertures 76 are separated from one another bybetween about 0.25 inches (6.35 mm) and about 0.375 inches (9.525 mm) inthe x-direction and between about 0.125 inches (3.175 mm) and about 0.75inches (19.05 mm) in the y-direction, any arrangement and density ofthese apertures 76 can be used. Alternatively, as shown in FIG. 6a, thearrangement of more numerous apertures 76 may be in an offset rowpattern. In such an arrangement, a plurality of straight rows ofapertures 76 are offset from each other so that apertures 76 in one rowdo not line up with the apertures 76 in the adjacent row, thus creatinga more condensed zigzag pattern. As shown in FIG. 7, apertures 76 do notextend into or through the second layer 62. The apertures 76 are formedby any suitable process, such as vacuum, needle or water jetperforation, laser, hot pins or mechanical punching, wherein theapertures 76 have a substantially circular geometry and a nominaldiameter of between about 0.060 inches (1.524 mm) and about 0.125 inches(3.175 mm). According to the dimensions of the first layer 60 and thenumber of apertures 76 therein, the average number of apertures 76 persquare inch is between about 0 and about 8. The apertures 76 can furtherhave any other geometry such as square or rectangular as seen in FIGS.10 and 11, respectively. Alternatively, the apertures 76 can be oval orellipse-shaped as seen in FIG. 12 or may comprise a series of slots asseen in FIG. 13.

[0102] As seen in FIGS. 7 and 8, the first surface area 64 and theportion of the second surface area 70 disposed outside of the firstsurface area 64 may be formed with a pattern or texture 78 by embossing,wherein the step of embossing occurs after the substrate is assembled.This pattern or texture of embossing can be seen on a back surface 80 ofthe second layer 62 as seen in FIG. 9.

[0103] In another embodiment, any of the above disclosed substrates maybe delivered to the consumer in roll form as seen in FIG. 14 so that theconsumer may cut the product to a desired length and/or shape using acutter bar, scissors, or knife. In a specific embodiment, the roll 98 isprovided in a box (not shown) with a cutter bar and the processingsubstrate is preferably of the type having a top cut resistant layer 100with perforated or punched holes 102, a middle absorbent layer 104, anda bottom barrier layer 106. The top and bottom barrier layers 100 and106 are both made of thermoplastic materials as discussed above.Preferably, but not necessarily, the top and bottom barrier layers 100and 106 are of the same width W1 that defines the width of the roll andthe absorbent layer 104 has width W2 less than the width WI of the topand bottom barrier layers 100. The layers 100 and 106 are directlysealed together along a length of the roll 98 from the edges of the roll107 up to a point 108 adjacent the absorbent layer 104. The layers 100and 106 are sealed together using a heat seal, a bar seal, adhesive, orany other method known in the art.

[0104] Preferably, bands of glue 109 are placed across the width of theroll 98 at increments along the roll 98, wherein the glue bands 109 sealthe layers 100 and 106 together at points where the layer 104 isinterrupted. The roll 98 can be cut or torn along any of the bands 109to create a processing substrate of a desired length. If the product iscut or torn along a portion proximate to a center of the glue bands 109,the glue bands 109 form a complete seal 110 around the absorbent layer104 to prevent leakage of fluids out of edges 112 of the processingsubstrate. If desired, the product may have perforations 114 as seen inFIG. 15 preferably located in the center of the glue bands 109 thatallow the consumer to tear off sheets as needed. Alternatively, theproduct may not include glue bands, and one or more perforations may bedisposed at one or more locations and extend through one or more of thelayers 100, 104, and 106.

[0105] The processing substrate 120 of FIG. 16 is similar to that ofFIG. 7 except that the tissue plies 66 and 72 of FIG. 7 are replaced bycrepe paper plies 122 and 124 that together form an absorbent layer 125having an enhanced absorbency. Specifically, a first layer 126 includesa thermoplastic ply 128 disposed above the crepe paper ply 122 whereinholes 130 are formed at spaced locations and extend through at least thethermoplastic ply 128. A second layer 132 includes the crepe paper ply124 disposed above a thermoplastic ply 134. The crepe paper plies 122and 124 provide more space for liquids to be held in the absorbent layer125 of the processing substrate 120. Similarly, as seen in FIG. 17, thetissue plies 66 and 72 may be replaced by plies of a paper materialhaving roughened surfaces 136 and 138 to increase the net thickness andthereby increase the holding capacity of the absorbent layer 125. Theroughened surfaces 136, 138 may be formed by picking or lifting thesurface of paper stock or brushing the paper stock with a wire roll orother suitable device.

[0106] In yet another embodiment, as seen in FIG. 18, a bilayer singleuse processing substrate 139 comprises a first two-ply cut-resistantlayer 140 and a second two-ply layer 142 similar to the embodiment ofFIGS. 5-9. The first layer 140 has a first surface area 144 and includesa bottom ply 146 which may be a hydrophilic material such as tissue, anoleophilic material such as a non-woven polypropylene, or a compositeoleophilic and hydrophilic material commingled normal to the substrate,for example by needlefelting, hydro entanglement, or pneumaticentanglement, and a top thermoplastic cut resistant ply 148. Apertures150 preferably extend through the entire first layer 140, but may extendonly through the top thermoplastic ply 148 of the first layer 140.Optionally, as seen in FIG. 19, a ply 158 which may be a hydrophilicmaterial such as tissue, an oleophilic material such as a non-wovenpolypropylene, or a composite oleophilic and hydrophilic material suchas a needlefelted composite of such materials may be disposed below thebottom ply 146 of the top layer 140. Further, a ply selected from thesame group of materials may be disposed below the top ply 154 of thebottom layer 142.

[0107] Other oleophilic materials include THINSULATE® by 3M®, polyester,finely spun polyolefins, materials coated with clays, or any other knownmaterials, wherein the oleophilic material absorbs oil based liquids,such as grease from fried foods. The second layer 142 has a secondsurface area 152 that is preferably (although not necessarily) largerthan the first surface area 144 and includes a top ply 154 which may bea hydrophilic material such as tissue, an oleophilic material such asthose disclosed above, or a composite oleophilic and hydrophilicmaterial as discussed above, disposed atop a thermoplastic barrier ply156. The thermoplastic material and tissue plies of both layers havethicknesses identical or similar to like layers of FIGS. 5-9. The layer140 may be centered atop the layer 142 and may be adhered or otherwisejoined thereto. It is advantageous in the embodiments of FIGS. 18 and 19to place an oleophilic layer above a hydrophilic layer, but is notnecessary.

[0108] Any of the embodiments as disclosed herein may include an odorabsorbing material within or applied to one or more of the layers. Forexample, an odor absorbent compound may be impregnated or otherwiseadded to either or both of the tissue plies, the crepe paper plies, theroughened paper plies or any other portion of the absorbent layer(s) ofthe processing substrate. Suitable odor absorbing materials includebaking soda, activated carbon, talc powder, cyclodextrin,ethylenediamine tetra-acetic acid, zeolites, antimicrobial agents,activated silica, activated charcoal, or any other materials known inthe art. In order to preserve the odor absorbing capacity of theabsorbent layer 170 before consumer use, one or more strips of tape 172can be attached to the top layer 174 of the processing substrate 176 asseen in FIG. 20. The strip(s) of tape 172 include a relatively low-tackadhesive and cover some or all the holes or apertures 178 in the toplayer 174 of the processing substrate 176 to keep the substrate 176 fromabsorbing odors prior to use. The strip(s) 172 are removed when aconsumer is ready to use the processing substrate 176.

[0109] Also, any or all of the layers of any of the embodimentsdisclosed herein may be tinted or otherwise processed to change colorwhen liquid is exposed thereto. For example, the bottom thermoplasticlayer of any of the embodiments presented herein may be tinted almostany color so that, when the absorbent layer becomes wet and changes fromopaque to translucent or nearly transparent, the color of thethermoplastic layer below the absorbent layer will become apparent. Amedium tint of any color (e.g., purple or blue) works most appropriatelybecause the color cannot be seen through the absorbent layer when theabsorbent layer is dry, but the color can be seen when the absorbentlayer is wet. Alternatively, a slighty darker tint of color may be usedwherein the color can be seen lightly through the absorbent layer whendry, but is much darker when the absorbent layer is wet.

[0110] Any of the processing substrates as disclosed herein may alsoinclude a cut-through indicator as seen in FIG. 21. In a preferredembodiment, a processing substrate 192 includes a first two-plycut-resistant layer 194 having a tissue ply 196 disposed below athermoplastic ply 198. The first two-ply layer 194 is disposed above asecond two-ply layer 200 that includes a tissue ply 202 disposed above athermoplastic ply 204, similar to the processing substrate of FIG. 7.The processing substrate 192 further includes a tissue layer 206disposed below the thermoplastic ply 204 of the second two-ply layer200. The tissue layer 206 may be a paper having a basis weight of 20pounds per 3000 ft², but is preferably a paper having a basis weight ofabout 10 pounds per 3000 ft². The thickness of the tissue layer 206 isbetween about 2 mils and about 6 mils thick (0.0508 mm-0.1524 mm). Inthe event that a user has cut through the plies 196, 198, 202, and 204,liquid exuded by the food being cut will be absorbed by the tissue layer206. This absorption can readily be seen by the user so that the usercan dispose the damaged substrate before damage to the underlyingsurface occurs and/or a mess has been made.

[0111] In another modification, the processing substrate shown in any ofthe previously discussed FIGS. can be improved to increase the flow offluid across the substrate, thereby allowing for more effectiveabsorption of fluids into the absorption layer. For example, in theembodiment seen in FIGS. 6 and 7 the thermoplastic material ply 68 (orany other ply and/or layer) can be treated with a wetting agent, such asDow Corning® Q2-5211 Superwetting agent. This treatment could beaccomplished before, during, or after assembly of the substate layers,and preferably prior to assembly thereof. Alternatively, thethermoplastic material ply 68 (or any other ply and/or layer) could betreated with a hydrophilic additive, such as Hydrophilic ConcentrateVW351 from Polyvel, Inc, of Hammonnton. N.J. Another option is toutilize an anti-fogging agent, such ChemStat AF-1006 from RutgersOrganics of State College, Pa. Preferably, any wetting agent,hydrophilic additive, or anti-fogging agent is of a food grade. Inanother alternative, the thermoplastic material ply 68 is corona treated(preferably prior to assembly of the layers), which serves to decreasethe surface tension of a liquid on the top layer 60 so that such liquidreadily flows into the absorbent portions of the processing substrate.

[0112] The plies and layers of the foregoing embodiments are producedvia known extrusion methods. A first sheet is produced having a cutresistant ply and an absorbent ply. Preferably, the cut resistant ply istreated before the two plies are combined. Referring now to FIG. 22, anapparatus for and method of applying a wetting agent, hydrophilicadditive, or anti-fogging agent 256 to the thermoplastic material ply 68is shown. The ply 68 is extruded by an extrusion apparatus 250 onto achilled casting roller 252. After being chilled by the casting roller252, the ply 68 traverses a path 253 to a pair of nip rollers 254. Spraynozzles 258 disposed along the path 253 spray a wetting agent orhydrophilic additive 256 onto the ply 68. Excess spray from the processcan be collected in a collecting tray 259 and reprocessed. Once the plyis treated, the cut resistant ply and absorbent ply are combined to forma first sheet. A second sheet having a liquid impermeable sheet is thenattached, preferably by an adhesive, to the absorbent ply of the firstsheet. Alternatively, the second sheet also has an absorbent ply and thetwo absorbent plies are attached together.

[0113] In an alternative method of application shown in FIG. 23, the ply68 is immersed in a liquid bath 260 containing a wetting agent,hydrophilic additive, or anti-fogging agent 256. Specifically, the ply68 is removed from the casting roller 252 by a pair of nip rollers 254.The pair of nip rollers 254 directs the ply 68 into the liquid bath 260.Once in the liquid bath 260, the ply 68 is immersed in the wetting agentor hydrophilic additive 256 and contacts secondary rollers 255 thatdirect the ply through the liquid bath 260 and into a vertical exit path261. Because the ply 68 exits the liquid bath 260 along the verticalexit path 261, any excess wetting agent, hydrophilic additive, oranti-fogging agent 256 can easily return to the liquid bath 260.

[0114] In yet another embodiment as seen in FIG. 24, a processingsubstrate 262 may include a first layer 264 of a paperboard material anda second polymeric layer 266 disposed below the first layer 264 andwhich is impervious to liquids. Preferably, although not necessarily,the first and second layers 264 and 266, respectively, are the samesize.

[0115] The paperboard material of the first layer 264 preferably,although not necessarily, has a dry basis weight of at least 150 poundsper 3000 ft², and more preferably a dry basis weight of at least 200pounds per 3000 f². Although paper is not inherently cut resistant, highdry basis weight paperboards begin to exhibit some cut resistantproperties. Any of the polymeric materials disclosed above can be usedto form the second polymeric layer 266, but low density polyethylene andpolypropylene are preferred materials. The thickness and sizes of thefirst and second layers 264 and 266, respectively, are similar toequivalent layers of the embodiments discussed herein.

[0116] A still further embodiment utilizes different adhesive patternsto improve liquid flow from the surface of the substrate. One suchadhesive pattern is discussed above in relation to FIGS. 5-9. FIG. 25illustrates another adhesive pattern wherein the adhesive lines of FIGS.5-9 extending continuously from side-to side of the first layer 60 arereplaced by discontinuous adhesive segments 300. The adhesive segments300 can be disposed in any regular or irregular (including random)pattern. In the illustrated embodiment, the adhesive segments 300 aresubstantially all of the same length and width and are disposedsubstantially parallel to one another in a regular pattern with theapertures 76 to form alternating rows of apertures 76 and segments 300.Preferably, a regular spacing exists between apertures in an x-directionand a y-direction such that rows of apertures are formed. Alsopreferably, each row of segments 300 is disposed at a locationequidistant to adjacent rows of apertures 76 (except at the top andbottom edges of the layer 60) and each row of apertures 76 is disposedsubstantially equidistant adjacent rows of segments 300 (again, exceptat the top and bottom edges of the layer 60), as seen in FIG. 25. Thus,for example, a first row 303 a comprising a series of segments 300 a1-300 a 23 is disposed in a linear fashion substantially midway betweenrows 301 a and 301 b of apertures 76. Similarly, a second row 303 bcomprising a further series of segments 300 b 1-300 b 24 is disposed ina linear fashion substantially midway between rows 301 b and 301 c ofapertures 76. The segments 300 a 1-300 a 23 are offset fromleft-to-right as seen in FIG. 25 with respect to the segments 300 b1-300 b 24. Preferably, each aperture 76 is disposed above (as seen inFIG. 25) a gap between adjacent ones of the segments 300 in the segmentrow immediately below the aperture 76. In addition, each aperture 76 isdisposed below a midpoint of a segment 300 in the segment rowimmediately above the aperture 76. Each of the segments 300 has aneffective length (i.e., a side-to-side dimension or extent as seen inFIG. 25) less than the width W of the layer 60, and, more preferably,greater than the distance between adjacent segments 300 of each row ofsegments 300. The segment and aperture patterns described above arerepeated over the entire surface area of the layer 60. The combinationof the segment pattern and the aperture pattern results in anadvantageous ready dispersion of liquid into the absorbent plies of theprocessing substrate as discussed above. This advantage of thisembodiment results from the ability of the liquid to flow from anaperture 76 not only between adjacent rows of segments 300, but alsothrough spaces between individual segments 300 of a row.

[0117] In an alternative embodiment, the adhesive portions could beapplied to the sheet in continuous lines and then areas of those linesbetween the adhesive segments 300 may be removed or rendered ineffectiveas an adhesive prior to securing the layers together. As in the previousembodiment, this results in a processing substrate wherein liquid canflow through the absorbent plies between adhesive segments of the samerow, as well as in the spaces between rows of adhesive segments. Thus,liquid can spread in as many directions as possible from the apertures76.

[0118] Also shown in FIG. 25 are two border adhesive strips 304 disposedparallel with and extending the width of the first layer 60. While theborder adhesive strips 304 strengthen the edge bond between layers theyare not a requirement. Also, as shown in FIG. 26, there may be twoadditional border strips extending the length of the first layer 60 toprovide additional strengthening of the layer edge bond.

[0119] Referring now to FIGS. 27 and 28, methods for applying theadhesive to the substrate are shown. The first layer 60 and second layer(not shown) are produced as discussed above. Then the adhesive segments300 are applied. In FIG. 27 the adhesive segments 300 are applied to thetissue or liquid absorbent ply 66 of the first layer 60. The applicationmethod includes the step of using an applicator 310 to deposit regularsized portions of adhesive onto the first layer 60 at regular intervals.The second layer is then attached to the tissue ply 66. Alternatively,the adhesive could be applied to the second layer in a similar mannerand the layers and can be assembled together.

[0120]FIG. 28 shows a different method for applying adhesive. In thismethod the adhesive 301 is applied in continuous strips 312 and thenportions 302 of the strips 312 are removed or rendered ineffective by aroller 316. The roller 316 includes circumferentially spaced lands orridges 318 that extend outwardly from a main roller body 320. The ridges318 are brought into contact with the first layer 60 as the roller 316is rotated and the strip 312 of adhesive 301 is removed or renderedineffective (i.e., non-flowable and/or non-sticky) where the ridge 318makes contact therewith. This can be accomplished in a variety of ways.In one embodiment, simple contact and/or compression by the ridge 318causes the adhesive to be driven into the absorbent ply of the layeraway from the surface thereof. Alternatively, such contact and/orcompression may cause the adhesive to adhere to the ridge 318 and to beremoved from the first layer 60. The portions may be removed from theridges 318 by cryogenic cleaning using dry carbon dioxide or nitrogen.In a further embodiment, a chemical or other agent carried by the ridgesbonds with the adhesive 301 so that the adhesive is unable to adhere toanother object. This agent could be of an organic or inorganic naturesuch as: talc; a silicon dioxide powder; flour or other starchcomposition; sawdust; paper fibers; a silicone mold release agent; orany anti-stick compounds such as canola oil, cooking sprays, or aTEFLON® agent. In any case, one or more portions 302 of each strip 312are “deactivated” as noted above (i.e., rendered ineffective) so thatwhen the first and second layers are assembled together, the adhesive inthe deactivated zones fails to spread into the absorbent ply of theadjacent layer at such locations, thereby preventing the formation ofliquid impervious zones at the areas where the ridges contacted theadhesive strip. As a result, liquid subsequently applied to thesubstrate liquid can spread out in a substantially radial pattern fromeach aperture.

[0121] Any other suitable method of removing or “deactivating” theadhesive can be used, as desired, to produce one or more discontinuousadhesive segments each having effective side-to-side dimensions (as seenin FIGS. 25 and 26) less than the width of the sheet 60. If desired, asseen in FIGS. 25 and 26, the segments may be separated from one anotherby distances less than the lengths of the segments.

[0122] As seen in FIGS. 29 and 30, a processing substrate 338 mayinclude an absorbent material layer 340 and randomly spaced strands ofmaterial 342 that are substantially continuous and preferably athermoplastic material disposed on a first side 344 of the absorbentmaterial layer 340. The randomly spaced strands 342 preferably provide atop surface that is cut resistant and liquid pervious. Almost any typeof thermoplastic material can be used to form the randomly space strands342, including but not limited to, polyolefins such as polyethylene andpolypropylene, polyvinyl chloride, polycarbonate, polylactic acid,thermosetting materials, or any type of thermoplastic material with anadditive or filler such as clay. Note that non-thermoplastic materialsare possible, but may not provide the necessary cut resistantproperties. The strands 342 may further be almost any size in diameterranging from about 20 microns to about 4 mm, depending on the use of theprocessing substrate.

[0123] The processing substrate 338 may also include a barrier layer 346attached to a second side 348 of the absorbent material layer 340 asseen in FIG. 31. The barrier layer 346 comprises a single polymeric orthermoplastic material ply 350, as discussed in detail above.Alternatively, as seen in FIGS. 32 and 33, the barrier layer 346includes a polymeric or thermoplastic material ply 350 disposed below anabsorbent material ply 352, also discussed in detail above. Further, therandomly spaced strands 342 and absorbent layer have a surface area 354that is smaller than a surface area 356 of the barrier layer 346.

[0124] The method of producing the processing substrates of FIGS. 29-33as seen in FIG. 34 includes the steps of providing the absorbentmaterial layer 340 and moving the absorbent material layer 340 in afirst direction 360. Thereafter, the method includes the step ofdepositing the randomly spaced strands of thermoplastic material 342onto the first side 344 of the absorbent material layer 340 to form thenecessary surface thereon. As the absorbent material layer 340 moves inthe first direction past an extrusion die 362, the randomly spacedstrands 342 are deposited through multiple spinnerets or small orifices364 onto the first side 344 of the absorbent material layer 340. Therandomly spaced strands 342 may be deposited on the entirety of theabsorbent material layer 340 or a smaller portion of the absorbentmaterial layer 340 as seen in FIGS. 32 and 33.

[0125] The extrusion die 362 is fixed relative to the first directionbut may move with respect to a second direction 366 that isperpendicular to the first direction. Preferably, the extrusion die 362rotates and oscillates as it is extruding the strands 342 onto theabsorbent material layer 340 to create the randomized pattern of strands342. Optionally, several extrusion dies 362 may be used at variouspoints in the path of the moving absorbent material layer 340. Stillfurther, air pressure through the use of pneumatic air devices may beused to manipulate the division of the strands of material 342.

[0126] Thereafter, the randomly spaced strands 342 may optionally becalendared to form flattened strands with spaces or voids therebetween.This step creates a flattened surface and fills in some of the voidspace between strands 342. Also optionally, a barrier layer 346 may bejoined to the second side 348 of the absorbent material layer 340 byextrusion coating, adhesive, or any other process as discussed in detailabove. As also discussed above, the barrier layer 346 may comprise asingle thermoplastic ply 350, a thermoplastic ply 350 disposed below anabsorbent ply, or any other combination of layers or plies.

[0127] Further specific examples of structures are given below:

EXAMPLE 1

[0128] a trilayer structure wherein the layer 16 comprises 5 mil (0.127mm) thick PP, filled with up to 40% mica and including {fraction(1/32)}″ diameter holes with 9 holes/square inch. The layer 18 is a 37#airlaid cellulose mat thermally laminated to a 5 mil (0.127 mm) thick PPbacking sheet comprising layer 20. The layer 16 is thermally bonded tothe layer 18.

EXAMPLE 2

[0129] a bilayer structure comprising a nonwoven polyolefin fabric upperlayer point bonded to a second layer of polymeric film that functionsboth as a barrier and as a cut resistant surface. During manufacture afood-contact approved surfactant may be applied to the upper layer toprovide a desired hydrophilic characteristic.

EXAMPLE 3

[0130] a scrim made of any of a variety of materials, such as athermoplastic or thermosetting polymeric material having voids betweenportions of material is post-filled with absorbent material, such ascellulose, using any suitable post-filling process, such as a wet-laidprocess or a vacuum process, to form a mat. A barrier layer of anysuitable material (e.g., PP or PE) is thereafter applied in any suitablemanner, such as by extrusion lamination, to an undersurface of the matand the mat is thereafter subjected to an embossing process either whilethe barrier layer is still partially molten and/or as heat is applied tocause the barrier layer to bond securely to the scrim.

EXAMPLE 4

[0131] a bilayer single use processing substrate comprises a first layer60, wherein the tissue ply 66 is 2.5 mils (0.0635 mm) thick and thethermoplastic material ply 68 is 5 mils thick (0.127 mm). The secondlayer 62 has a tissue ply 72 which is 2.5 mils (0.0635 mm) thick and athermoplastic material ply 74 which is 3.5 mils (0.0889 mm) thick,wherein the first layer 60 is secured atop the second layer 62 by anethyl vinyl acetate adhesive.

[0132] Each of the thermoplastic material plies consists of a resincomprising an isotactic copolymer metallocene polypropylene, wherein themetallocene polypropylene comprises 99.9 percent by weight of apropylene monomer and 0.1 percent by weight of an ethylene monomer. Theresin comprises 93.873 percent by weight of the metallocenepolypropylene, 6.050 percent by weight of a talc additive, 0.055 percentby weight of calcium stearate, 0.011 percent by weight of a primaryantioxidant, and 0.011 percent by weight of a secondary antioxidant.

[0133] The first and second layer tissue plies 66, 72 comprise 98percent by weight of a virgin hardwood and softwood wood pulp, 0.2percent by weight of a polyamide wet strength resin and trace amounts ofa defoamer, a dryer release agent, two creping agents, a repulping aidand a bleach neutralizer.

[0134] The first layer 60 has dimensions of 9.75 inches (247.65 mm) by7.688 (195.275 mm) inches and the second layer 62 has dimensions of11.75 (298.45 mm) inches by 9.688 inches (246.075 mm). The first layer60 includes 414 regularly spaced apertures created by having a nominaldiameter of 0.08 inches (2.032 mm), wherein the apertures form a zigzagpattern and are separated from one another by 0.279 inches (7.0866 mm)in the x-direction and 0.165 inches (4.191 mm) in they-direction. Theaverage number of apertures per square inch is 5.52.

[0135] The first surface area 64 and the portion of the second surfacearea 70 disposed outside of the first surface area are embossed with anembossing pattern 78.

[0136] One or more of the following benefits may be obtained, dependingupon the choice of material(s), properties and material amounts:

[0137] 1. the sheet absorbs food juices while cutting and reducesresulting mess;

[0138] 2. the sheet is easy to dispose of;

[0139] 3. the sheet reduces or even prevents accidental germ/microbialcontamination because the germs from one food item will not gettransferred to another if the cutting sheet is disposed of after use;

[0140] 4. the sheet provides cut resistance, i.e., it helps reduce anycut damage to the kitchen or other work surface;

[0141] 5. the sheet does not allow food juices to run all over the worksurface;

[0142] 6. the sheets may be provided in varying sizes to suit thecutting or other task;

[0143] 7. the sheet may be used on top of a cutting board or directly onthe work surface;

[0144] 8. the sheet reduces slippage, by providing a skid-resistantcontact with the work surface;

[0145] 9. after cutting, one need only lift the sides of the sheet tofunnel food into a cooking pot;

[0146] 10. the sheet can be set on a surface to catch debris and grease;

[0147] 11. the sheet is easily rolled up with waste captured therein anddisposed of in the trash can;

[0148] 12. since each sheet is clean the need for repeated cleaning ofthe cutting board or other work surface is avoided;

[0149] 13. the sheet can be used to cut or process any food or othermaterial including meat, chicken, fish, soft or hard fruits andvegetables, dough, etc. . . . ;

[0150] 14. unlike using a paper towel, the sheet does not permit fiberand lint to become attached to the food being cut;

[0151] 15. the sheet does not transfer any smell or taste to the productbeing cut or otherwise processed (alternatively, the sheet could beimpregnated with a desirable scent, such as lemon, which is thentransferred to the item being processed);

[0152] 16. the sheet manages bacteria by absorption, containment andbarrier rather than by the use of added chemicals;

[0153] 17. the sheet can be made food contact approved;

[0154] 18. the top surface reduces slippage of food while cutting;

[0155] 19. the cutting surface will not dull knives like some hardcutting surfaces;

[0156] 20. the sheet is hygienic;

[0157] 21. the sheet may be formed with at least one and, preferablymultiple absorbent edges that give an extra measure of security tomanage bacteria-borne juices;

[0158] 22. the sheet offers superior food/surface protection fornon-cutting food preparation applications;

[0159] 23. the sheet affords an easy, convenient medium for in-home orout-of-home, recreational and outdoor uses;

[0160] 24. the sheet can be cut by consumers to other sizes and/orshapes;

[0161] 25. the sheet can be held in place on countertops by a few dropsof water;

[0162] 26. the sheet protects the countertop and food from potentiallydeadly pathogens that cannot be seen;

[0163] 27. the sheet allows safer food preparation for the consumer andthe consumer's family by reducing the risk of food-borne illness;

[0164] 28. the sheet can reduce food preparation time;

[0165] 29. the profile and/or texture of the cutting surface can becustomized to provide benefits not practical in conventional cuttingsurfaces or boards simply because such articles would be difficult orimpossible to wash;

[0166] 30. the sheets do not take up room in the dishwasher or in thebags and wraps drawer of the kitchen;

[0167] 31. in alternative embodiments bacteria borne liquids aresecurely trapped in cells and/or a layer below the cutting surface;

[0168] 32. the sheet may be constructed so that the consumer can see theabsorption of liquid;

[0169] 33. the sheet may be made to have a clean hygienic appearance;

[0170] 34. the sheet may have a decorative appearance that is printedand/or embossed as desired;

[0171] 35. the sheet absorbs like a paper towel, but has the additionaladvantages of barrier and cut resistance;

[0172] 36. the sheet has additional uses, for example, as a placemat, ascounter protection for use around stove/cook top, bin/shelf protectionin refrigerator, under dog or cat dish, under plants, under largeserving dishes, etc. . . . ;

[0173] 37. in some embodiments the sheet has a place to wipe a knife on;

[0174] 38. the sheet can make a desirable addition to a picnic basket;

[0175] 39. the sheet can be used to line a refrigerator meat tray;

[0176] 40. the sheet absorbs and contains all juices from defrostingmeat;

[0177] 41. the sheet can contain odors from foods, such as fish;

[0178] 42. the sheet can be used on dishes and platters to preventscratching of same by knives;

[0179] 43. the sheet can be placed under sticky and dripping containersin refrigerator;

[0180] 44. the sheet does not fall apart like paper towels; and

[0181] 45. the sheet could be used as a drawer liner or as a mat to doart projects on.

INDUSTRIAL APPLICABILITY

[0182] The present invention is not limited to the concept of utilizingand constructing disposable, absorbent barrier surfaces in place ofand/or in conjunction with conventional cutting boards, but encompassesall food handling, article support and barrier/isolation applicationswhere absorbent, liquid/bacteria barrier management is desirable andmethods for making the same.

[0183] Numerous modifications to the present invention will be apparentto those skilled in the art in view of the foregoing description.Accordingly, this description is to be construed as illustrative onlyand is presented for the purpose of enabling those skilled in the art tomake and use the invention and to teach the best mode of carrying outsame. The exclusive rights to all modifications which come within thescope of the appended claims are reserved.

We claim:
 1. A single use processing substrate, comprising; a firstcut-resistant layer having a first surface area and including anabsorbent ply and a thermoplastic material ply; and a second layerhaving a second surface area and including an absorbent ply and athermoplastic material ply; wherein the thermoplastic material ply ofthe second layer is tinted a certain color for indicating absorption ofthe absorbent ply of the second layer.
 2. The single use processingsubstrate of claim 1, wherein the first layer is secured to the secondlayer such that a portion of the second surface area is laterallydisposed outside of the first surface area.
 3. The single use processingsubstrate of claim 1, wherein the first layer includes aperturestherein.
 4. The single use processing substrate of claim 3, wherein theapertures are circular in shape.
 5. The single use processing substrateof claim 1, wherein the thermoplastic material ply of the first layer isdisposed above the absorbent ply of the first layer.
 6. The single useprocessing substrate of claim 5, wherein the thermoplastic material plyof the second layer is disposed below the absorbent ply of the secondlayer.
 7. The single use processing substrate of claim 1, wherein thesecond layer absorbent ply allows the certain color to be enhanced whenthe second layer absorbent ply absorbs liquid.
 8. A single-useprocessing substrate, comprising: a first material having aliquid-permeable, cut resistant surface; a second material disposedadjacent the first material and having a liquid-absorbent portion; athird material disposed adjacent the second material and having aliquid-impermeable portion, wherein the third material is tinted acertain color to indicate absorption of the absorbent portion.
 9. Thesingle use processing substrate of claim 8, wherein the first materialincludes apertures therein.
 10. The single use processing substrate ofclaim 9, wherein the apertures are circular in shape.
 11. The single useprocessing substrate of claim 1, wherein the second, absorbent materialallows the certain color to show through when the second, absorbentmaterial absorbs liquid.
 12. A single-use processing substrate,comprising: first means for providing a liquid-permeable, thermoplastic,cut resistant surface having apertures therein; second means disposedadjacent the first means and providing means for providing aliquid-absorbent portion; third means disposed adjacent the second meansand providing means for providing a liquid-impermeable portion; andfourth means for providing an indication of absorption of the secondmeans.
 13. The single use processing substrate of claim 12, wherein thefourth means includes tinting the third means a certain color.
 14. Thesingle use processing substrate of claim 13, wherein the second meansfor providing a liquid-absorbent portion allows the certain color to beenhanced when fluid is absorbed therein.